Hako Jonas 1200 D User manual

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Sweepmaster P/D/B 1200 RH

(6300.10 / 6300.20 / 6300.30)

Training

Troubleshooting

Adjustments

Components/Suppliers

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

From may 2014 the machine names are changed. The „old“ name Jonas for sit-on sweepers is changed into Sweepmaster for all

sweepers. The differentiation which machine is it exactly is done by the indication of kind of drive, sweeping width and operation

concept (close to the old Hakomatics). In this training manual are the old names used. Here a comparison of the „old“ and „new“

names for this machine.

Jonas 1200 V Sweepmaster P 1200 RH

Jonas 1200 D Sweepmaster D 1200 RH

Jonas 1200 E Sweepmaster B 1200 RH

P means petrol-/gasoline-, D means diesel- and B stays for battery-model. The LP driven machines are still an option and didn´t have

an own name. The R means, it´s a sit-on machine and the H stays for high dump.

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

JONAS 1200 V / D / E ......................................................................................................... FEHLER! TEXTMARKE NICHT DEFINIERT.

1.0 OPERATION ..................................................................................................................................................................................... 6

1.1 Scheme of Operation ...................................................................................................................................................................................................................... 7

2.0 TECHNICAL DATA ........................................................................................................................................................................... 8

3.0 DESIGN AND MECHANICS............................................................................................................................................................ 12

3.1 Operation Elements ...................................................................................................................................................................................................................... 13

3.2 Cylindrical Broom and Side Brush ............................................................................................................................................................................................. 14

3.2.1 Cylindrical Broom .................................................................................................................................................................................................................... 14

3.2.1.1 Replace Cylindrical Broom ............................................................................................................................................................................................... 14

3.2.1.2 Check Sweeping Mark Distance ...................................................................................................................................................................................... 15

3.2.1.3 Adjust Sweeping Mark Distance ...................................................................................................................................................................................... 15

3.2.2 Side Brush ............................................................................................................................................................................................................................... 16

3.3 Dirt Hopper ABBA System ........................................................................................................................................................................................................... 18

3.4 Dirt Hopper Lift-Out System ........................................................................................................................................................................................................ 20

3.5 Filter ............................................................................................................................................................................................................................................... 21

3.5.1 Change and Clean Cartridge Filter ......................................................................................................................................................................................... 21

3.5.2 Suction Fan Flap ..................................................................................................................................................................................................................... 21

3.6 Steering.......................................................................................................................................................................................................................................... 22

3.7 V/D-Version Travelling Drive ....................................................................................................................................................................................................... 23

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.8 E-Version Travelling Drive ........................................................................................................................................................................................................... 24

3.8.1 Bearing Plate ........................................................................................................................................................................................................................... 24

3.8.2 Change Brushes ...................................................................................................................................................................................................................... 25

4 DRIVE .............................................................................................................................................................................................. 26

4.1 V-Version Engine .......................................................................................................................................................................................................................... 27

4.1.1 Engine ..................................................................................................................................................................................................................................... 27

4.1.2 LPG Version ............................................................................................................................................................................................................................ 29

4.2 D-Version Engine .......................................................................................................................................................................................................................... 32

5 HYDRAULIC SYSTEM .................................................................................................................................................................... 34

5.1 General........................................................................................................................................................................................................................................... 35

5.2 Brief Description of V/D Travel Drive .......................................................................................................................................................................................... 35

5.2.1 Hydraulic Diagram V/D-Version Driving .................................................................................................................................................................................. 36

5.2.2 Drive Pump .............................................................................................................................................................................................................................. 37

5.3 Brief Description of Work Hydraulic ........................................................................................................................................................................................... 38

6 ELECTRICAL SYSTEM .................................................................................................................................................................. 39

6.1 Safety Information ........................................................................................................................................................................................................................ 40

6.2 View on V/D-Version Fuse Box ................................................................................................................................................................................................... 41

6.3 View on E-Version Fuse Box ....................................................................................................................................................................................................... 43

6.4 Seat Contact Controller................................................................................................................................................................................................................ 45

6.4.1 Circuit Diagram ........................................................................................................................................................................................................................ 45

6.4.2 Logic ........................................................................................................................................................................................................................................ 46

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

6.5 Drive Controller ............................................................................................................................................................................................................................. 47

6.5.1 Error Messages ....................................................................................................................................................................................................................... 49

6.5.2 Machine Safety Functions ....................................................................................................................................................................................................... 50

6.6 Electric Drive Motor ...................................................................................................................................................................................................................... 51

6.7 Low Discharge Signal Sender (LDS) .......................................................................................................................................................................................... 52

6.7.1 LDS Setting Mode ................................................................................................................................................................................................................... 52

6.6.2 LDS Programming ................................................................................................................................................................................................................... 54

7 MAINTENANCE .............................................................................................................................................................................. 56

7.1 Gasoline-Version Service Intervals ..................................................................................................................................................................................... 57

7.2 Diesel-Version Service Intervals .......................................................................................................................................................................................... 59

7.3 E-Version Service Intervals .................................................................................................................................................................................................. 61

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

1.0 Operation

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

1.1 Scheme of Operation

Functional details: The side brush (1) removes dirt from corners and edges and allows enlarging work width and area performance

on free surfaces. The cylindrical broom (2) collects the dirt to throw it overhead into the dirt hopper (3). The collected fine dust is drawn

in by suction fan and separated by the filter system (4). Clean air only is taken out into the environment. Disposal of dirt is realized via

high-dump system directly into a standard dustbin.

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

2.0 Technical Data

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Jonas 1200V

Jonas 1200D

Jonas 1200E

Dimensions and weights

Length incl. side broom mm 1,998 1,998 1,998

Width w/o side broom mm 1,142 1,142 1,142

Width with 1 side broom mm 1,142 1,142 1,142

Width with 2 side brooms mm 1,142 1,142 1,142

Height above driver seat mm 1,520 1,520 1,520

Turning radius mm 3300 3300 3300

Empty weight kg 763 784 1,105

Adm. total weight kg 1,056 1,074 1,395

Riding and sweeping performance

Forward driving speed km/h 0 – 9 0 – 9 0 - 8

Wheel speed at max. velocity rpm 156 156 139

Reverse driving speed km/h 0 – 4 0 – 4 0 - 4

Wheel speed at max. velocity rpm 58 58 58

Max. sweeping speed (recommended: 4.0 km/h) km/h 9.0 9.0 8.0

Sweeping width with/w/o side broom mm 850 / 1,150 850 / 1,150 850 / 1,150

Sweeping width with 2 side brooms mm 1,470 1,470 1,470

Theor. sweeping performance with 1 / 2 side broom(s) m²/h 10,300 / 13,200 10,300 / 13,200 9,200 / 11,700

Climbing ability % 18 18 16

Filter system

Filter surface m² 4.8 4.8 4.8

Plate filter qty. 1 1 1

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Jonas 1200V

Jonas 1200D

Jonas 1200E

Cylindrical broom

Length / diameter mm 800 / 430 800 / 430 800 / 430

Wear limit mm 350 350 350

Speed rpm

500 ± 20 500 ± 20 500 ± 20

Distance between sweeping marks mm 70 + 10 70 + 10 50 + 5

Qty. of bristles qty. 12 V-shape 12 V-shape 12 V-shape

Standard bristling PA PA PES

Sealing strip ground clearance (broo

m compartm.)

left / right / rear mm 1 / 1 / 4 1 / 1 / 4 1 / 1 / 4

front mm 0 0 0

Side broom

Diameter mm 600 600 600

Speed rpm 85 85 85

Standard bristling PA PA PE

Dirt hopper

Hopper volume l 130 130 130

Wheels

Front wheel drive (solid rubber) 4.00-4 4.00-4 4.00-4

Rear wheels (pneumatic) 4.00-8 4.00-8

Inflation pressure bar 6 6

Optional rear wheel option (solid rubber) (Standard E) 4.00-8 4.00-8 4.00-8

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Jonas 1200V

Jonas 1200D

Jonas 1200E

Engine

Manufacturer Briggs&Stratton Lombardini

Type Vanguard V-Twin LDW 502

Work cycles / quantity of cylinders 4-stroke / 2 4-stroke / 2

Capacity cm³ 480 505

Power (at 2,550 rpm) kW 8.2 6.3

Service speed (all consumers on) rpm 2,550 + 50 2,550 + 50

Fuel tank capacity l 25 25

Consumption l/h 2.5 1.25

Engine oil / filling Type / l 15W-40 / 1.5 15W-40 / 1.5

Spark plug Champion RC 12

YC

Hydraulic system

Hydraulic fluid (e.g. Mobiloil) DTE 15 M DTE 15 M DTE 15 M

Tank capacity l 22 22 13

Electric

al system

Starter battery V / Ah 12 / 74 12 / 45 (24 / )

Generator A 13 13

Total output kW 3.10

Output of drive motor kW 1.10

Output of hydraulic drive kW 2 x 1.00

Noise emission value

Sound pressure level acc. to DIN IEC 60335-2-72 dB(A) 78 79 71

Sound power level acc. to DIN IEC 60335-2-72 dB(A) 94 95 88

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.0 Design and Mechanics

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.1 Operation Elements

Mitnehmer

Feder

Carrier spring

Hydraulikventil

Hydraulic valve

Mitnehmer

Welle

Carrier shaft

The spring connected to the side broom lever should be slightly under tension. The tension must not exceed the tension of the valve-

neutral-spring (hydraulic broom valve).

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.2 Cylindrical Broom and Side Brush

3.2.1 Cylindrical Broom

3.2.1.1 Replace Cylindrical Broom

Dismounting: Mounting:

• Lower broom Proceed in inverse order

• Remove l-h lateral cover

• Loosen star-shape knob (2) to remove l-h broom arm (1) Note:

• Open both knobs (3+5) and remove lateral plate (4); Twist broom while inserting until it audibly catches

pull out the cylindrical broom in the driving tooth

1

2

3

4

5

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.2.1.2 Check Sweeping Mark Distance

• Take machine to level concrete or asphalt ground

(check inflation pressure of machines equipped with pneumatic tyres and correct pressure if required)

• Switch on cylindrical broom and let it run briefly while vehicle is standing

• Lift up and switch off the cylindrical broom, forward machine a short distance and measure dimensions of sweeping marks

With correct adjustment of the cylinder broom, the marks left on the ground have to be in parallel. The distance between parallel

sweeping marks of the Jonas 1200 E should amount to 50 + 5 mm, that of the Jonas 1200 V/D to: 70 +10 mm.

Note: Exceeding the specified width has a negative effect on the service life of the cylindrical broom.

The distances between marks reduce as the cylinder broom diameter reduces due to bristle wearing.

3.2.1.3 Adjust Sweeping Mark Distance

Adjust the sweeping mark distance by turning the hand wheel located under the engine compartment cover. The “mark pin” indicates

wear limit of the cylindrical broom.

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.2.2 Side broom

Provide for side brush inclination such that the contact surface covers about

2

/

3

of the brush circumference.

Seen in direction of travel, the floor contact surface of the r-h side brush should be between the 11 and 3 o’clock position.

l-h side brush between the 9 and 1 o’clock position

Adjusting paral

lelism

• Loosen l-h half-bearing of torsion shaft

• Adjust parallelism with stop screw

Half-bearing

Torsion shaft

Stop screw

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Height adjustment

Roll

for Bowden cable

Return spring

Inclination of 5° fixed

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.3 Dirt Hopper ABBA System

Cyl. broom shift wheel

Cable cord for

cyl. broom

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

Tracking of the Dirt Hopper

Service Manual

Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014

Confidential - For internal use only!

3.4 Dirt Hopper Lift-Out System

The ball head (ABBA

system) catches here

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